fbm - production process planning

8/8/2019 Fbm - Production Process Planning

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PRODUCTION PROCESS PLANNING


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HISTORY

EVOLVED OVER A PERIOD OF TIME

THIS TOOK PLACE WHERE

-THERE WAS AN ABUNDANCE OFLABOUR

- CHEAP RENTAL SPACE

TASKS WERE DIVIDED INTOPARTIES

- SIMILAR TASKS, WITH NUMEROUS

FOODS, MANY PEOPLE


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HISTORY

IN THE LAST 30 YEARS THINGS BEGAN TO CHANGE

RESEARCH BY SUPPLIERS

RISING LABOUR COSTS INCREASE OF CATERING COSTS

RISING RENTAL COSTS


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PRODUCTION METHODS

1. CONVENTIONAL METHODS

-Traditional Partie Method

- Production with convenience foods


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Traditional Partie Methods

Food purchased raw

Little of convenience food

Facilities provided for receipt and storage of

goods, the preparation, cooking, holding andservice of food, dishwashing facilities.

Labor is intermittent poor utilization of plant

Poor use of fuel

Expensive to run manpower, space, energy

requirements


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Raw Food Supplies

Dry GoodsChill/ Frozen

Store

Food Production Parties

Serve

Sauce Roast Fish Larder Soup Vegetable Pastry

Serve


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CONVENTIONAL PRODUCTION WITH

CONVENIENCE FOODS CAN BE INTRODUCED INTO A TRADITIONAL KITCHEN

- RANGE FROM PARTIAL TO COMPLETE

- BEST USE CAN ONLY BE SEEN BY A MEANS OF A PLANNED CATERING

SYSTEM

BEST IN RELATION TO A SYSTEMS APPROACH THAT THE OPERATION BECONSIDERED AS A WHOLE

IF INTRODUCED INTO A TRADITIONAL KITCHEN THE EFFECTS ON

- LABOUR

- EQUIPMENT

- SPACE

- CUSTOMER


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ADVANTAGES OF CENTRALISED

PRODUCTION

NO PEAKS AND TROUGHS

CONCENTRATION OF SKILLED STAFF AT CPU

HIGHER PERFORMANCE AND QUALITY.

SATELLITE KITCHENS NON SKIILED BULK PURCHASING REDUCES RAW MATERIAL

COST AND OVERALL FOOD COST/MEAL

INTRODUCTION OF THE STORAGE STAGE

IMPROVES EFFICIENCY OF KITCHEN STAFF AND

EQUIP

BETTER WORKING AND SOCIAL HOURS

SCHEDULING DROPS ENERGY CONSUMPTION


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DISADVANTAGES OF CENTRALISED

PRODUCTION

HIGH COST OF CONSTRUCTION

UNLESS UTILISED PROPERLY COST/MEAL CAN RISE

PRODUCTION FAILURES POWER OUTAGES,

HYGIENE OF FOOD CONTAMINATON CAN QUICKLYESCLATE QUICKLY.


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Fresh Food Supplies Frozen Food Supplies

Dry food / chill store Freezer Store

Central Preparation

Blast Chilling to 0 C 3 C

Chill store Transport to

Peripheral units

Chill Store

Reheating to service

requirements

Serve

Reheating to service

requirements

Serve


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BASIC PRINCIPLES OF COOK FREEZE

AND COOK CHILL SYSTEMS

All raw food should be of good microbiological quality

Initial cooking will ensure destruction of vegetative stages

of any pathogenic micro organisms present

Spores rapid rising of temperature to above 60 C.( 7C 60C) restricts growth.

Cross contamination between raw and cooked food.

Physical separation Pre-preparation and cooking areas

Storage and distribution conditions must be strictlycontrolled to ensure quality and safety.

Reheating and service conditions must be strictly adhered to, to

ensure safety with the temperature of all food being strictly

monitored.


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Quality of Raw Food

1. General storage conditions:

Loss will occur fresh vegetables prior to cooking or in

water after preparation. Kept under right temperature foras short as possible.

2. The type of Processing:

Overcooking, over regeneration, poor refrigeration

storage, and delay between re-heating and consumption alladd to vitamin loss and palatability.


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Cook Freeze Production

Full Cooking followed by fast freezing, with

storage at a controlled temp of 18C. It is the

complete food production process from the

initial raw food to the final service of the

product.


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Cook Freeze Production Process

1. Raw food should be purchased against a tight

specification to ensure quality and consistency.

- Laboratory testing of all incoming food. (large

Operations)- Standard checking procedure

- Inspection of suppliers premises.

- Regular checks on quantity and control

procedures.


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2. Food Storage:

- All foods kept under strict temperature control

- Hygienic conditions

- without any cross contamination- Strict rotations of stock


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3. Pre preparation:

- Includes all preparation of foods prior to

cooking.

- Standard procedure to keep this stage of theprocess separate from the next stage

- Restrict all staff handling raw food to this area


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4. Cooking:

- Should be done in small batches.

- Internal temperatures to reach 70C.

- Recipes may be adjusted for the length of timeof storage


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5. Portioning

- Hot food should be portioned into single or

multi-portioned containers to a depth of50mm

- kept in a blast freezer- within 30 minutes after cooking


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6. Blast chilling

- 0 C to 3 C

- within 90 minutes of being placed inside the

Freezer- preserves food quality

- prevents bacteria


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7. Chill Freezing:

- shelf life of cooked foods is a maximum of5

days. Inclusive of production, distribution and

regeneration.- stored between 0 C to 3 C

- prevents bacterial growth and cross

contamination.

- each container should be clearly marked:Product name, batch number, production date,

and expiry date. This aids stock rotation.


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8. Distribution:

- should only take place in refrigerated or

insulated containers.

- increase in temperature till 5 C is allowed- after which it should be brought down rapidly

to 0 C to 3 C.

- if temperature rises to 5 C to 10 C. food should

be consumed within 12 hrs- if temperature exceeds 10 C food needs to be

destroyed.


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9. Regeneration:

- must be regenerated within 30 mins after taking

out of chill store.

- food must be reheated to 70 C and held therefor 2 mins


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BEVERAGE PRODUCTION METHODS

Beverage includes both alcoholic and non-alcoholic

beverages.

1. Raw beverages:

- these are products that require a higher degree of

preparation (tea, coffee, cocoa)

- usually far away from the service area. OR

included into the facilities of the restaurants and

coffee shops itself.


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2. Semi prepared beverages:

-These are beverages that do not need to beprepared from the raw stage. (cordials, iced tea,

cold coffee, cocktails)

- the preparation may be part of the service itself


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3. Fully prepared beverages:

- Beverages that do not require any preparation- bottled fruit juices, spirits, bottled aerated

drinks, wines.

- dispensed in front of the customer


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THINGS TO KEEP IN MIND FOR BEVERAGE

PRODUCTION

Keep equipment clean and hyginic

Check equipment regularly

operates within the financial limits of theorganization

good quality raw ingredients

fbm - production process planning

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